Electromechanical equipment fault judgment method and system

Abstract

According to the electromechanical equipment fault judgment method and system provided by the invention, accurate inversion is carried out on the real working temperature of the conductor wire in the wire based on the physical parameters, the current working condition and the surface temperature data of the wire, so that the electromechanical equipment can obtain the internal thermal state of the wire online in real time; compared with a traditional mode depending on manual regular inspection or maintenance after a fault, the timeliness and precision of wire state sensing are greatly improved. By combining the actual temperature value of the conductor wire with the normal working temperature range and the designed service life parameter of the conductor wire, an overload early warning can be output in advance when the temperature of the conductor wire is close to or exceeds an allowable range, and the risk that electromechanical equipment is shut down and even fires are caused due to insulation aging, breakdown, short circuit and strand breakage is reduced; and the service life consumption of the wire can be subjected to long-term cumulative evaluation, so that the overall operation safety and reliability of electromechanical equipment are improved, and accidental shutdown and maintenance cost are reduced.

Description

Technical Field

[0001] This invention relates to the technical field of fault diagnosis methods for electromechanical equipment, and in particular to a fault diagnosis method and system for electromechanical equipment. Background Technology

[0002] Electromechanical equipment consists of a combination of various electronic components connected by wires, enabling these components to work together to allow the machine to operate.

[0003] In existing electromechanical equipment, wires are used for connection. These wires are in a state of continuous energization. During the energization process, heat is generated in the wires. The insulation layer wrapped around the conductive wire will age under continuous high temperature. If this is not detected in time, it will eventually lead to the insulation layer being broken, short circuit, poor contact, broken strands of the wires, etc., ultimately causing the electromechanical equipment to malfunction.

[0004] Existing testing methods can only wait for human inspectors to perform the tests or for the electromechanical equipment to malfunction and require repair. This makes it impossible to determine the internal condition of the wires in a timely manner when they are about to age or short-circuit.

[0005] Secondly, the conductive wires inside the conductor will generate heat. If the current is too large during operation, or if the resistance is too high due to aging, the temperature will be too high. Once the temperature exceeds its operating range, it will cause a short circuit in the conductive wire, which will create a fire hazard. Summary of the Invention

[0006] Therefore, it is necessary to propose a method and system for diagnosing mechanical and electrical equipment faults in response to the above problems.

[0007] This application provides a method for diagnosing faults in electromechanical equipment, the method comprising: Obtain the parameter data of the target conductor and generate the first parameter data; Real-time acquisition of current data when the target conductor is energized, generating the first current data; The resistive loss is calculated based on the first parameter data and the first current data to obtain the first loss value; The equivalent radial thermal resistance is calculated based on the first parameter data; Real-time acquisition of the surface temperature of the target conductor, generating a first temperature value; The temperature of the conductive wire inside the target conductor is calculated based on the equivalent radial thermal resistance, the first loss value, and the first temperature value to obtain the actual conductive wire temperature value. The target conductor is evaluated based on the actual conductor temperature value and the first parameter data to generate an evaluation result.

[0008] In at least one embodiment of this application, the first parameter data includes: the conductor diameter of the target wire, the length of the target wire, the AC correction factor of the target wire conductor, the resistivity of the target wire conductor material, the normal operating temperature range of the target wire, the thermal conductivity of the insulating material, and the outer diameter of the insulating layer.

[0009] In at least one embodiment of this application, the step of calculating resistive loss based on the first parameter data and the first current data to obtain a first loss value includes: The cross-sectional area is calculated based on the conductor diameter of the target wire, and the target conductor cross-sectional area is generated; The unit resistance value of the target conductor is calculated based on the resistivity of the conductor material and the cross-sectional area of ​​the target conductor. Calculate the total resistance of the entire target conductor based on the unit resistance value and the length of the target conductor; The AC equivalent resistance value is calculated based on the AC correction factor and the total resistance value of the target conductor.

[0010] In at least one embodiment of this application, the step of calculating resistive loss based on the first parameter data and the first current data to obtain a first loss value further includes: The effective AC current value is calculated based on the first current data; The first loss value is calculated based on the AC effective current value and the AC equivalent resistance value.

[0011] In at least one embodiment of this application, the step of calculating the equivalent radial thermal resistance based on the first parameter data includes: The radial thermal resistance per unit length is calculated based on the diameter of the target conductor, the outer diameter of the insulation layer, and the thermal conductivity of the insulation material. The equivalent radial thermal resistance is calculated based on the length of the target conductor and the radial thermal resistance per unit length.

[0012] In at least one embodiment of this application, the specific steps of evaluating the target conductor based on the actual conductive wire temperature value and the first parameter data to generate an evaluation result include: The normal operating temperature range includes a lower temperature limit and a higher temperature limit; If the actual conductor temperature is greater than the upper limit of the normal operating temperature range, an overload signal is generated. If the actual conductor temperature is not greater than the upper limit of the normal operating temperature range, then the next monitoring cycle will begin.

[0013] In at least one embodiment of this application, the specific steps for real-time acquisition of the surface temperature value of the target conductor and generation of the first temperature value include: The maximum value is selected from the surface temperature values ​​of the target conductor and used as the first temperature value.

[0014] In at least one embodiment of this application, the specific steps of evaluating the target conductor based on the actual conductive wire temperature value and the first parameter data to generate an evaluation result further include: Obtain the design life value of the target conductor at rated temperature; Based on the actual conductor temperature value and the designed life value, the actual life consumption value of the target conductor is calculated according to the preset temperature and life correspondence relationship; During each test, the actual lifespan consumption value of the target conductor is accumulated.

[0015] In at least one embodiment of this application, the method further includes: Obtain the ambient temperature at which the target conductor operates, and correct the actual conductor temperature value based on the ambient temperature.

[0016] This application provides a fault diagnosis system for electromechanical equipment, used to execute the fault diagnosis method for electromechanical equipment described in any one of the above-mentioned methods, the system comprising: The acquisition module is used to acquire the parameter data of the target conductor and generate the first parameter data; The acquisition module is used to acquire the current data and surface temperature value of the target conductor in real time when it is energized, and generate the first current data and the first temperature value. The calculation module is used to calculate the resistive loss based on the first parameter data and the first current data to obtain the first loss value, and to calculate the equivalent radial thermal resistance and the actual conductor temperature value. The evaluation module evaluates the target conductor based on the actual conductor temperature value and the first parameter data to generate evaluation results.

[0017] The electromechanical equipment fault diagnosis method and system implemented in this embodiment will have at least the following beneficial effects: The above-mentioned method and system for diagnosing mechanical and electrical equipment faults accurately inverts the actual working temperature of the internal conductive wires based on the physical parameters, current conditions, and surface temperature data of the conductors. This enables the mechanical and electrical equipment to know the internal thermal state of the conductors online and in real time. Compared with the traditional method of relying on manual periodic inspections or post-fault repairs, it greatly improves the timeliness and accuracy of conductor status perception.

[0018] By combining the actual conductor temperature with the conductor's normal operating temperature range and design life parameters, overload warnings can be issued in advance when the conductor temperature approaches or exceeds the allowable range, reducing the risk of equipment shutdown or even fire caused by insulation aging, breakdown, short circuit, and broken strands. Furthermore, the long-term cumulative assessment of conductor life consumption can be conducted, thereby improving the overall safety and reliability of the equipment and reducing unexpected downtime and maintenance costs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] in: Figure 1 This is a flowchart of a method for diagnosing mechanical and electrical equipment faults in one embodiment; Figure 2 This is a partial detailed flowchart of a method for diagnosing mechanical and electrical equipment faults in one embodiment; Figure 3 This is a flowchart illustrating the evaluation results of a fault diagnosis method for electromechanical equipment in one embodiment. Figure 4 This is a flowchart of a method for determining mechanical and electrical equipment faults in another embodiment; Figure 5 This is a structural block diagram of an electromechanical equipment fault diagnosis system in one embodiment.

[0021] Explanation of main component symbols 100. Mechanical and electrical equipment fault diagnosis system; 110. Acquisition module; 120. Data collection module; 130. Calculation module; 140. Evaluation module. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] This application provides a method for diagnosing faults in electromechanical equipment, the method comprising: S101. Obtain the parameter data of the target conductor and generate the first parameter data.

[0024] S102. Real-time acquisition of current data when the target conductor is energized, generating the first current data.

[0025] S103. Calculate the resistive loss based on the first parameter data and the first current data to obtain the first loss value.

[0026] S104. The equivalent radial thermal resistance is calculated based on the first parameter data.

[0027] S105. Real-time acquisition of the surface temperature value of the target conductor, generating the first temperature value.

[0028] S106. Calculate the temperature of the conductive wire inside the target conductor based on the equivalent radial thermal resistance, the first loss value, and the first temperature value to obtain the actual conductive wire temperature value.

[0029] S107. The target conductor is evaluated based on the actual conductor temperature value and the first parameter data to generate an evaluation result.

[0030] Please refer to Figures 1-4 In this embodiment, before the electromechanical equipment is put into operation, the parameter data of the target conductor is first obtained to generate the first parameter data.

[0031] During the operation of electromechanical equipment, current data when the conductor is energized is collected in real time by a current detection element installed on the target conductor, and the first current data is generated.

[0032] The current sensing element can be a Hall current sensor, a current transformer, or a sampling resistor and analog-to-digital converter circuit, etc., and the installation location can be chosen close to the power supply end of the electromechanical equipment or the critical load end. By continuously acquiring the current waveform of the target conductor under different operating conditions, the system can obtain information such as the corresponding effective current value.

[0033] The controller calculates the resistive loss based on the first parameter data and the first current data to obtain the first loss value.

[0034] The controller can calculate the resistance of the conductor by considering the resistivity of the conductor material, the cross-sectional area of ​​the conductor, and the length of the conductor. Then, by taking into account the AC correction factor of the conductor, the resistance under DC conditions is converted into the AC equivalent resistance corresponding to the current frequency. Finally, the power loss model is used to calculate the resistive heating power of the conductor under the current current conditions.

[0035] This heat generation power is the first loss value, characterizing the heat generated by the conductor due to its own resistance per unit time. By evaluating the conductor's heating based on the resistive loss of the conductor itself, the intensity of the internal heat source in the conductor can be accurately reflected.

[0036] The equivalent radial thermal resistance is calculated based on the first parameter data. The equivalent radial thermal resistance is used to characterize the ease with which the internal conductive wires of the conductor transfer heat to the outer surface through the insulation layer. It depends on the conductor diameter, the outer diameter of the insulation layer, and the thermal conductivity of the insulation material.

[0037] In specific calculations, the conductive wire can be regarded as a cylindrical heat source, and the insulation layer covering it can be regarded as a coaxial circular heat-conducting medium. The radial thermal resistance per unit length of the wire from the conductor to the outer surface of the insulation can be calculated based on the heat conduction theory. Then, combined with the actual wire length, the equivalent radial thermal resistance of the entire target wire can be obtained.

[0038] By introducing an equivalent radial thermal resistance, this embodiment explicitly distinguishes the temperature difference between the internal conductor and the external surface along the heat conduction path, and provides differentiated temperature estimation models for conductors with different diameters, insulation thicknesses, and materials from a structural perspective.

[0039] During the operation of electromechanical equipment, the temperature acquisition unit collects the surface temperature value of the target conductor in real time and generates a first temperature value. The temperature acquisition unit can be a temperature sensor mounted on the outside of the conductor insulation layer, such as a thermistor, platinum resistance thermometer, or flexible temperature patch. The installation method can use thermally conductive adhesive or fixing clamps to make it as close as possible to the outer surface of the conductor to ensure the accuracy of the temperature response.

[0040] By periodically collecting the surface temperature of the conductor, this embodiment obtains the real-time temperature boundary conditions of the conductor's outer surface. Real-time acquisition of the first temperature value enables continuous tracking of the conductor's temperature change trajectory, providing basic data for subsequent temperature rise rate analysis and abnormal behavior identification, and significantly improving the timeliness of temperature monitoring.

[0041] The controller calculates the temperature of the internal conductive wire of the target conductor based on the equivalent radial thermal resistance, the first loss value, and the first temperature value, thereby obtaining the actual conductive wire temperature value.

[0042] When the conductor is in thermal equilibrium or near-steady condition, the first loss value can be considered as the heat power generated by the conductor, and the equivalent radial thermal resistance can be considered as the thermal impedance from the conductor to the outer surface. Then, the temperature difference between the conductor and the outer surface is approximately proportional to the product of the two values, and thus the true temperature of the internal conductor can be calculated given the temperature of the outer surface. Even under rapidly changing conditions, the temperature calculation results can be corrected by combining a dynamic thermal model.

[0043] The actual operating temperature of the internal conductive wires can be obtained while the wires remain intact, without damaging the insulation or adding additional internal sensors.

[0044] After obtaining the actual conductor temperature value, the system further evaluates the target conductor based on the actual conductor temperature value and the first parameter data to generate an evaluation result.

[0045] The actual conductor temperature is compared with the normal operating temperature range in the first parameter data. When the actual temperature exceeds the upper limit of the allowable temperature, it is determined that the current conductor is in an overload or abnormal operating condition, and an overload signal or fault warning is generated.

[0046] By combining the design life of the conductor at the rated temperature and the relationship between temperature and life, the actual conductor temperature value is mapped to the life consumption per unit time. The life consumption is accumulated during multiple tests to form the life consumption ratio and remaining life estimate of the conductor, thereby realizing a quantitative assessment of the long-term aging degree of the conductor.

[0047] The accurate inversion of the actual operating temperature of the conductor's internal conductive wires based on the conductor's physical parameters, current conditions, and surface temperature data enables electromechanical equipment to obtain the internal thermal state of the conductor online and in real time. Compared with the traditional method of relying on manual periodic inspections or post-fault repairs, this significantly improves the timeliness and accuracy of conductor status perception.

[0048] By combining resistive loss calculation with equivalent radial thermal resistance calculation, the differences in conductor material characteristics, wire diameter, insulation thickness and thermal conductivity are fully considered, avoiding the error of simply estimating the internal temperature by the surface temperature, and making fault judgment based on a quantitative model that is more in line with physical reality.

[0049] By combining the actual conductor temperature with the conductor's normal operating temperature range and design life parameters, overload warnings can be issued in advance when the conductor temperature approaches or exceeds the allowable range, reducing the risk of equipment shutdown or even fire caused by insulation aging, breakdown, short circuit, and broken strands. Furthermore, the long-term cumulative assessment of conductor life consumption can be conducted, thereby improving the overall safety and reliability of the equipment and reducing unexpected downtime and maintenance costs.

[0050] The target conductor refers to any one or a group of conductors installed inside electromechanical equipment, in a powered state, and responsible for transmitting electrical energy.

[0051] The first set of parameters should include at least the target conductor's diameter, length, resistivity of the conductor material, correction factor for AC operation, thermal conductivity of the insulation material, outer diameter of the insulation layer, and the conductor's normal operating temperature range. These parameters are generally available from conductor nameplates, technical manuals, or production data and are inherent properties of the conductor.

[0052] In at least one embodiment of this application, the first parameter data includes: the conductor diameter of the target wire, the length of the target wire, the AC correction factor of the target wire conductor, the resistivity of the target wire conductor material, the normal operating temperature range of the target wire, the thermal conductivity of the insulating material, and the outer diameter of the insulating layer.

[0053] Please refer to Figures 1-4 In this embodiment, the first parameter data includes the conductor diameter of the target wire, the length of the target wire, the AC correction factor of the target wire conductor, the resistivity of the conductor material, the normal operating temperature range of the target wire, the thermal conductivity of the insulating material, and the outer diameter of the insulating layer.

[0054] By collecting the above parameters, this embodiment can establish an electrical and thermal model consistent with the target conductor structure and material properties, providing the necessary data foundation for resistive loss calculation, equivalent radial thermal resistance derivation, and internal conductive wire temperature inversion.

[0055] Among them, the conductor diameter, resistivity, and wire length determine the resistance value and heating capacity of the wire under different current conditions.

[0056] The AC correction factor is used to correct resistance changes caused by factors such as the skin effect under AC operating conditions.

[0057] The thermal conductivity of the insulating material and the outer diameter of the insulating layer determine the heat dissipation capacity of the conductor.

[0058] The normal operating temperature range provides a clear benchmark for determining whether the conductor is in a safe operating condition.

[0059] It can form differentiated judgment models for conductors of different specifications, materials and structures, which significantly improves the accuracy and adaptability of conductor condition assessment and reduces the risk of misjudgment due to missing or mismatched parameters.

[0060] In at least one embodiment of this application, the step of calculating resistive loss based on the first parameter data and the first current data to obtain a first loss value includes: S201. Calculate the cross-sectional area based on the conductor diameter of the target wire to generate the target conductor cross-sectional area.

[0061] S202. Calculate the unit resistance value of the target conductor based on the resistivity of the target conductor material and the cross-sectional area of ​​the target conductor.

[0062] S203. Calculate the total resistance value of the entire target conductor based on the unit resistance value and the length of the target conductor.

[0063] S204. Calculate the AC equivalent resistance value based on the AC correction factor and total resistance value of the target conductor.

[0064] Please refer to Figures 1-4 In this embodiment, the cross-sectional area of ​​the conductor is first determined based on the conductor diameter. Then, the resistance value per unit length is calculated using the resistivity of the conductor material and the cross-sectional area. Finally, the total resistance of the entire conductor is obtained by combining the actual length of the conductor.

[0065] Under AC operating conditions, the conductor resistance is affected by the skin effect, proximity effect, etc. Therefore, this embodiment further corrects the total resistance based on the AC correction factor to obtain an AC equivalent resistance value that is more in line with the actual operating conditions.

[0066] Finally, the resistive loss of the conductor can be calculated based on the current data and the AC equivalent resistance value, thereby obtaining the first loss value that accurately reflects the internal heating intensity of the conductor.

[0067] The formula for calculating the cross-sectional area of ​​the target conductor is: Where S is the cross-sectional area of ​​the target conductor and d is the diameter of the target wire conductor.

[0068] The formula for calculating the resistance per unit length is: Where R1 is the resistance per unit length. Let S be the resistivity of the conductor material, and S be the cross-sectional area of ​​the conductor.

[0069] The formula for calculating total resistance is: Where R0 is the total resistance and L is the length of the target wire. It is a multiplication sign.

[0070] The formula for calculating the equivalent resistance value of AC is: , where k is the AC correction factor for the target conductor.

[0071] By introducing an AC correction factor, the heat generation calculation can be adapted to the AC power supply scenarios commonly used in electromechanical equipment, thereby improving the accuracy of the loss value.

[0072] The first loss value obtained can be directly used for internal temperature inversion and fault risk assessment, which helps to identify risks of increased resistance due to aging or abnormal heating due to overload in advance, enhances the operational safety of electromechanical equipment, and reduces the probability of unexpected failures.

[0073] In at least one embodiment of this application, the step of calculating resistive loss based on the first parameter data and the first current data to obtain a first loss value further includes: S205. The effective AC current value is calculated based on the first current data.

[0074] S206. Calculate the first loss value based on the AC effective current value and the AC equivalent resistance value.

[0075] Please refer to Figures 1-4 In this embodiment, the effective AC current value is calculated based on the first current data to reflect the true current-carrying capacity of the target conductor under AC operating conditions.

[0076] Then, the effective AC current value is combined with the calculated AC equivalent resistance value, and the resistive heat generation of the conductor under the current operating state is calculated using the power loss formula, which is the first loss value.

[0077] The controller squares the first current data, then averages and takes the square root to obtain the effective AC current value.

[0078] The formula for calculating the effective alternating current value is as follows: Where I1 is the effective AC current value, Let be the instantaneous current value obtained from the a-th sampling, and N be the total number of sampling points.

[0079] The formula for calculating the first loss value is as follows: Where P1 is the first loss value and R2 is the AC equivalent resistance value.

[0080] By incorporating effective AC current into the calculation process, the current-carrying capacity of the conductor in the actual AC power supply environment can be accurately described, avoiding the deviation in loss assessment caused by directly using peak current or instantaneous current.

[0081] The combination of AC effective current and AC equivalent resistance makes resistive loss calculation more in line with actual working conditions, and can truly reflect the heat intensity generated inside the conductor due to the current passing through it.

[0082] The first loss value obtained in this way can be used for internal conductor temperature inversion, and can also serve as an important basis for judging whether the conductor is overloaded, aged or has an abnormally increased resistance, which helps to improve the accuracy and stability of the assessment of the operating status of electromechanical equipment.

[0083] In at least one embodiment of this application, the step of calculating the equivalent radial thermal resistance based on the first parameter data includes: S301. Calculate the radial thermal resistance per unit length based on the diameter of the target conductor, the outer diameter of the insulation layer, and the thermal conductivity of the insulation material.

[0084] S302. The equivalent radial thermal resistance is calculated based on the length of the target conductor and the radial thermal resistance per unit length.

[0085] Please refer to Figures 1-4 In this embodiment, based on the diameter of the target conductor, the outer diameter of the insulation layer, and the thermal conductivity of the insulation material, the conductor and its outer insulation layer are regarded as a coaxial cylindrical heat conduction structure, and the radial thermal resistance per unit length of the conductor from the conductor to the outer surface of the insulation layer is calculated.

[0086] Based on the actual length of the target conductor, the radial thermal resistance per unit length is converted according to the length to obtain the equivalent radial thermal resistance of the entire target conductor, which is used to characterize the overall thermal resistance encountered when the heat generated inside the conductor is transferred to the outer surface of the conductor.

[0087] The formula for calculating radial thermal resistance per unit length is as follows: Where R3 is the radial thermal resistance per unit length, r2 is half the outer diameter of the insulation layer, r1 is the radius of the target conductor, and K is the thermal conductivity of the insulation material. is the natural logarithm, and / is the division sign.

[0088] The formula for calculating the equivalent radial thermal resistance is as follows: Where R4 is the equivalent radial thermal resistance.

[0089] This significantly improves the accuracy of subsequent calculations when inverting the internal conductive wire temperature based on resistive losses and surface temperature, avoiding temperature estimation errors caused by ignoring size and material differences.

[0090] It can adapt to wires of different specifications, insulation materials and lengths, improving the versatility and reliability of fault diagnosis methods for electromechanical equipment.

[0091] In at least one embodiment of this application, the specific steps of evaluating the target conductor based on the actual conductive wire temperature value and the first parameter data to generate an evaluation result include: The normal operating temperature range includes a lower temperature limit and a higher temperature limit.

[0092] S303. If the actual conductor temperature is greater than the upper limit of the normal operating temperature range, an overload signal is generated.

[0093] S304. If the actual conductor temperature value is not greater than the upper limit of the normal operating temperature range, then proceed to the next monitoring cycle.

[0094] Please refer to Figures 1-4 In this embodiment, the normal operating temperature range preset in the first parameter data is used to refine the range into a lower temperature limit and a higher temperature limit, so as to clarify the temperature range that the target conductor is allowed to operate safely for a long time.

[0095] The actual conductor temperature value calculated in real time is compared with the upper temperature limit. When the actual conductor temperature value is greater than the upper temperature limit of the normal operating temperature range, it is determined that the target conductor is in an abnormal high temperature or overload state, and an overload signal is immediately generated to indicate that there is a risk of abnormal conductor heating in the electromechanical equipment.

[0096] When the actual conductor temperature is not greater than the upper temperature limit, the conductor is considered to be in an acceptable working state, no alarm is triggered, and the monitoring and calculation of the next cycle begins, so as to achieve continuous tracking of the conductor's operating status.

[0097] By directly linking the actual conductor temperature value with the conductor's normal operating temperature range, the evaluation dimensions consider both real-time operating conditions and the conductor's design capability as a judgment criterion, thus achieving a clear overload judgment basis based on physical quantities.

[0098] It can generate an overload signal as soon as the conductor temperature exceeds the allowable range, exposing risks such as abnormal conductor heating, insulation aging, or excessive load in advance. This allows maintenance personnel or the upper control system to take timely measures such as load limiting, shutdown, or maintenance, thereby reducing the probability of conductor insulation breakdown, short circuit, and damage to electromechanical equipment or even fire accidents caused by these factors, and significantly improving the safety and reliability of electromechanical equipment operation.

[0099] In at least one embodiment of this application, the specific steps for real-time acquisition of the surface temperature value of the target conductor and generation of the first temperature value include: S401. Select the maximum value from the surface temperature values ​​of the target conductor as the first temperature value.

[0100] Please refer to Figures 1-4 In this embodiment, the controller arranges multiple temperature acquisition points on the outer surface of the target conductor to obtain the surface temperature values ​​of the conductor at different locations in real time.

[0101] Since local hot spots may appear in the conductor during operation due to local aging, poor contact or uneven heat dissipation, the maximum value is selected as the first temperature value from the multiple surface temperature values ​​collected.

[0102] By selecting the location with the highest temperature as the representative temperature, it can be ensured that potential hot spots inside the conductor are not masked by the average temperature.

[0103] It can effectively capture abnormal local temperature rises of conductors during operation, avoiding underestimation of the conductor's thermal state due to the use of single-point temperature or average temperature.

[0104] Especially in the early stages of faults such as local insulation aging or poor contact of crimped terminals, the temperature in hot spots often rises first. By extracting the maximum temperature value, these early anomalies can be reflected more promptly, which is helpful for identifying potential thermal hazards that may lead to short circuits or broken strands in advance, and improving the sensitivity and reliability of fault diagnosis of electromechanical equipment.

[0105] In at least one embodiment of this application, the specific steps of evaluating the target conductor based on the actual conductive wire temperature value and the first parameter data to generate an evaluation result further include: S501. Obtain the design life value of the target conductor at the rated temperature.

[0106] S502. Based on the actual conductor temperature value and the designed life value, calculate the actual life consumption value of the target conductor according to the preset temperature and life correspondence relationship.

[0107] S503. During each test, the actual lifespan consumption value of the target conductor is accumulated.

[0108] Please refer to Figures 1-4 In this embodiment, the design life value of the target conductor at the rated temperature is obtained. This life value is usually provided by the conductor manufacturer and is used to characterize the service life of the conductor under long-term stable operating conditions.

[0109] The actual conductor temperature value calculated in real time is correlated with the designed life value. Based on the preset temperature-life correspondence (e.g., based on the Arrhenius aging model, the lifespan is halved for every 10°C increase), the actual lifespan consumption value of the target conductor under the current temperature conditions is calculated to reflect the aging rate of the conductor at different temperature levels.

[0110] Throughout the operation of the electromechanical equipment, the system accumulates the life consumption value during each detection, thereby forming the cumulative life consumption of the target conductor over time, providing a basis for predicting the remaining life of the conductor.

[0111] By continuously accumulating lifespan consumption values, it is possible to identify situations where conductors are operating at high temperatures for extended periods, leading to rapid lifespan degradation. This alerts maintenance personnel to replace the conductors while they are still within their usable range, effectively preventing serious risks such as insulation breakdown and short circuits, and further enhancing the safety of electromechanical equipment operation.

[0112] In at least one embodiment of this application, the method further includes: S601. Obtain the ambient temperature at which the target conductor operates, and correct the actual conductor temperature value based on the ambient temperature.

[0113] Please refer to Figures 1-4 In this embodiment, the system collects the ambient temperature of the space where the electromechanical equipment is located or the surrounding area of ​​the target conductor through an ambient temperature sensor, such as the temperature inside the power distribution cabinet or the temperature of the equipment compartment.

[0114] After obtaining the ambient temperature, the controller combines the heat dissipation characteristics of the conductor, the installation method, and the influence of ambient temperature on heat dissipation conditions in the first parameter data to correct the calculated actual conductor temperature value, so that the corrected conductor temperature is closer to the actual thermal state of the conductor under real environmental conditions.

[0115] For example, when the ambient temperature is significantly higher than the standard test temperature (such as 25°C or 40°C), the internal temperature assessment value can be increased; in scenarios with lower ambient temperatures and better heat dissipation, the sensitivity to temperature exceeding the limit can be appropriately reduced, so that the temperature assessment results match the actual operating environment.

[0116] The corrected formula is: Where T0 is the corrected actual temperature of the conductor, T1 is the uncorrected temperature of the conductor calculated based on loss and thermal resistance, T2 is the ambient temperature collected in real time, and T3 is the reference ambient temperature (such as 25℃ or the rated test temperature of the conductor).

[0117] By introducing an ambient temperature correction process, the problem of ignoring external heat exchange conditions when simply estimating the internal temperature based on the conductor's own parameters and loss model is avoided. This allows the conductor temperature assessment to be dynamically adjusted according to the actual installation scenario of the electromechanical equipment, thereby improving the accuracy and reliability of temperature judgment.

[0118] It can reduce false alarms caused by "normal high temperature" being misjudged as overload due to high ambient temperature, and also avoid underreporting of the actual thermal risk of conductors under high ambient temperature, which is more conducive to making reasonable and accurate judgments on the safe operating status of electromechanical equipment.

[0119] A fault diagnosis system 100 for electromechanical equipment is provided for executing the fault diagnosis method for electromechanical equipment described in any one of the above-mentioned methods. The system includes: The acquisition module 110 is used to acquire the parameter data of the target conductor and generate the first parameter data.

[0120] The acquisition module 120 is used to acquire the current data and surface temperature value of the target conductor when it is energized in real time, and generate the first current data and the first temperature value.

[0121] The calculation module 130 is used to calculate the resistive loss based on the first parameter data and the first current data to obtain the first loss value, and to calculate the equivalent radial thermal resistance and the actual conductor temperature value.

[0122] Evaluation module 140 evaluates the target conductor based on the actual conductor temperature value and the first parameter data to generate evaluation results.

[0123] Please refer to Figure 5In this embodiment, the acquisition module 110 is used to acquire parameter data of the target conductor and generate first parameter data. This module can extract information such as conductor diameter, conductor length, resistivity, AC correction factor, outer diameter of insulation layer, thermal conductivity of insulation material, and normal operating temperature range of the target conductor from equipment installation documents, conductor model database, or preset parameter library.

[0124] The acquisition module 120 is used to acquire the current data and surface temperature value of the target conductor in real time when it is energized, and generate the first current data and the first temperature value. This module may include components such as Hall current sensors, current transformers, patch temperature sensors or flexible temperature measuring strips.

[0125] The acquisition module 120 can not only capture the dynamic current generated by the target conductor as the load changes, but also monitor the temperature changes on the outer surface of the conductor. Among them, the acquired surface temperature data is filtered by the system to obtain the first temperature value, which is used to reflect the instantaneous thermal state of the outer surface of the conductor and provide boundary conditions for internal temperature inversion.

[0126] The calculation module 130 is used to calculate the resistive loss based on the first parameter data and the first current data to obtain the first loss value, and to calculate the equivalent radial thermal resistance and the actual conductor temperature value.

[0127] Based on the conductor structure and material parameters provided by the acquisition module 110, the calculation module 130 first calculates the AC equivalent resistance of the conductor under the current operating conditions, and then combines the real-time current data to obtain the resistive loss.

[0128] The equivalent radial thermal resistance was then calculated using the geometric and thermal conductivity properties of the conductor and the insulating layer.

[0129] Finally, the actual conductor temperature inside the conductor is calculated based on resistive loss, equivalent radial thermal resistance, and outer surface temperature.

[0130] The evaluation module 140 is used to evaluate the target conductor based on the actual conductor temperature value and the first parameter data to generate an evaluation result.

[0131] The assessment results may include comparing the actual conductor temperature with the conductor's normal operating temperature range to determine whether there is a risk of overload, insulation aging, or short circuit.

[0132] By combining temperature change trends to identify whether there are local abnormal heating points in the conductor, calculating the life consumption based on the correlation between temperature and lifespan, and accumulating the results in multi-cycle testing to form a life decay curve, thus achieving long-term health management of the conductor.

[0133] The final evaluation results output by the evaluation module 140 can be used to trigger alarms, prompt maintenance, or link electromechanical equipment to perform protective actions.

[0134] The electromechanical equipment fault diagnosis system can continuously and accurately assess the internal thermal state of wires without disassembling or damaging them, enabling real-time monitoring of wire health during equipment operation and significantly improving the safety, reliability, and timeliness of equipment maintenance.

[0135] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0136] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for diagnosing faults in electromechanical equipment, characterized in that, The method for diagnosing mechanical and electrical equipment faults includes: Obtain the parameter data of the target conductor and generate the first parameter data; Real-time acquisition of current data when the target conductor is energized, generating the first current data; The resistive loss is calculated based on the first parameter data and the first current data to obtain the first loss value; The equivalent radial thermal resistance is calculated based on the first parameter data; Real-time acquisition of the surface temperature of the target conductor, generating a first temperature value; The temperature of the conductive wire inside the target conductor is calculated based on the equivalent radial thermal resistance, the first loss value, and the first temperature value to obtain the actual conductive wire temperature value. The target conductor is evaluated based on the actual conductor temperature value and the first parameter data to generate an evaluation result.

2. The method for diagnosing mechanical and electrical equipment faults according to claim 1, characterized in that, The first parameter data includes: the conductor diameter of the target conductor, the length of the target conductor, the AC correction factor of the target conductor, the resistivity of the conductor material of the target conductor, the normal operating temperature range of the target conductor, the thermal conductivity of the insulating material, and the outer diameter of the insulating layer.

3. The method for diagnosing mechanical and electrical equipment faults according to claim 2, characterized in that, The step of calculating resistive loss based on the first parameter data and the first current data to obtain the first loss value includes: The cross-sectional area is calculated based on the conductor diameter of the target wire, and the target conductor cross-sectional area is generated; The unit resistance value of the target conductor is calculated based on the resistivity of the conductor material and the cross-sectional area of ​​the target conductor. Calculate the total resistance of the entire target conductor based on the unit resistance value and the length of the target conductor; The AC equivalent resistance value is calculated based on the AC correction factor and the total resistance value of the target conductor.

4. The method for diagnosing mechanical and electrical equipment faults according to claim 3, characterized in that, The step of calculating resistive loss based on the first parameter data and the first current data to obtain the first loss value further includes: The effective AC current value is calculated based on the first current data; The first loss value is calculated based on the AC effective current value and the AC equivalent resistance value.

5. The method for diagnosing mechanical and electrical equipment faults according to claim 2, characterized in that, The step of calculating the equivalent radial thermal resistance based on the first parameter data includes: The radial thermal resistance per unit length is calculated based on the diameter of the target conductor, the outer diameter of the insulation layer, and the thermal conductivity of the insulation material. The equivalent radial thermal resistance is calculated based on the length of the target conductor and the radial thermal resistance per unit length.

6. The method for diagnosing mechanical and electrical equipment faults according to claim 2, characterized in that, The specific steps for evaluating the target conductor based on the actual conductor temperature value and the first parameter data to generate an evaluation result include: The normal operating temperature range includes a lower temperature limit and a higher temperature limit; If the actual conductor temperature is greater than the upper limit of the normal operating temperature range, an overload signal is generated. If the actual conductor temperature is not greater than the upper limit of the normal operating temperature range, then the next monitoring cycle will begin.

7. The method for diagnosing mechanical and electrical equipment faults according to claim 1, characterized in that, The specific steps for real-time acquisition of the target conductor surface temperature value and generation of the first temperature value include: The maximum value is selected from the surface temperature values ​​of the target conductor and used as the first temperature value.

8. The method for diagnosing mechanical and electrical equipment faults according to claim 1, characterized in that, The specific steps for evaluating the target conductor based on the actual conductor temperature value and the first parameter data to generate an evaluation result further include: Obtain the design life value of the target conductor at rated temperature; Based on the actual conductor temperature value and the designed life value, the actual life consumption value of the target conductor is calculated according to the preset temperature and life correspondence relationship; During each test, the actual lifespan consumption value of the target conductor is accumulated.

9. The method for diagnosing mechanical and electrical equipment faults according to claim 1, characterized in that, The method further includes: Obtain the ambient temperature at which the target conductor operates, and correct the actual conductor temperature value based on the ambient temperature.

10. A fault diagnosis system for electromechanical equipment, used to execute the fault diagnosis method for electromechanical equipment as described in any one of claims 1-9, characterized in that, The system includes: The acquisition module is used to acquire the parameter data of the target conductor and generate the first parameter data; The acquisition module is used to acquire the current data and surface temperature value of the target conductor in real time when it is energized, and generate the first current data and the first temperature value. The calculation module is used to calculate the resistive loss based on the first parameter data and the first current data to obtain the first loss value, and to calculate the equivalent radial thermal resistance and the actual conductor temperature value. The evaluation module evaluates the target conductor based on the actual conductor temperature value and the first parameter data to generate evaluation results.

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